Method of sealing a capacitor fill port

ABSTRACT

An apparatus comprising a capacitor stack, including one or more substantially planar anode layers, and one or more substantially planar cathode layers. Additionally, the capacitor has a case having a first opening and a second opening, the first opening sized for passage of the capacitor stack, and a cover substantially conforming to the first opening and sealingly connected to the first opening. Also, the capacitor includes a plate substantially conforming to the second opening and sealingly connected to the second opening, the plate defining an aperture. Additionally, the capacitor includes a plug substantially conforming to the aperture in the plate, the plug sealingly connected to the plate. The capacitor stack is disposed in the case, and the terminal is in electrical connection with the case and at least one capacitor electrode.

CLAIM OF BENEFIT OF PRIOR-FILED APPLICATION

This patent application is a divisional patent application of U.S.patent application Ser. No. 11/182,487, entitled “Plug for Sealing aCapacitor Fill Port,” filed Jul. 15, 2005, which claims the benefit ofU.S. Provisional Application Ser. No. 60/588,617, entitled “Plug forSealing a Capacitor Fill Port,” filed on Jul. 16, 2004, the entirespecification of each of which is incorporated herein by reference.

FIELD OF THE INVENTION

This disclosure relates generally to capacitors, and more particularly,to compact, electrolytic, flat high voltage electrolytic capacitors madefrom substantially planar layers.

BACKGROUND

A capacitor is an electric circuit element used to store chargetemporarily, consisting in general of two metallic plates separated andinsulated from each other by a dielectric. Capacitors are useful as acompact source for a high energy pulse.

In many instances, the capacitor takes the form of an aluminumelectrolytic capacitor. Existing designs include one or more separatorsdisposed between two or more sheets of aluminum foil. One of the foilsserves as the anode of the capacitor, and the other serves as thecathode. Some designs include multiple foils which are interconnected toincrease effective size of the anode or cathode.

Varying devices benefit from compact capacitor designs. Implantablecardioverter defibrillators are typically implanted in the left regionof the chest or in the abdomen, and include a housing and one or moreleads implanted in the patient. Existing implantable cardioverterdefibrillator designs include capacitors which can consume 30% of thevolume of the housing. A need exists for a smaller device which iscapable of delivering patient therapy. One way to obtain a smallerdevice is to reduce capacitor size. Capacitor size can be reducedthrough a reduction in capacitor component size. Making a capacitor casethinner is one way to reduce capacitor size.

However, a thin case can raise additional issues. For example, thincases increase manufacturing difficulty. Increased manufacturingdifficulty can result in higher costs. What is needed is a case which isthin, and which is compatible with a variety of manufacturing processes.

SUMMARY

The above-mentioned problems and others not expressly discussed hereinare addressed by the present subject matter and will be understood byreading and studying this specification.

In varying embodiments, the presents subject matter includes anapparatus, comprising a capacitor stack, including one or moresubstantially planar anode layers, and one or more substantially planarcathode layers, a case having a first opening and a second opening, thefirst opening sized for passage of the capacitor stack; the secondopening defined by walls having a first thickness, a cover substantiallyconforming to the first opening and sealingly connected to the firstopening, a plate substantially conforming to the second opening, theplate substantially conforming to the second opening, and sealinglyconnected to the second opening, the plate having a second thicknesswhich is approximately greater than the first thickness of the wallsdefining the second opening, the plate defining an aperture, a plugsubstantially conforming to the aperture in the plate, the plugsealingly connected to the plate, and a terminal connected to the plate.Additionally, the present subject matter includes an apparatus whereinthe capacitor stack is disposed in the case, and the terminal is inelectrical connection with the case and at least one capacitorelectrode.

Additionally, the present subject matter includes a method, comprisingassembling a capacitor stack out of electrodes which approximate layers,placing the capacitor stack in a case with a first opening and a secondopening, the first opening sized for the passage of the capacitor stack,the second opening defined by walls having a first thickness, insertinga plate in the second opening from the inside of the case, the plateadapted to mate to the second opening, and having a thickness which isapproximately greater than the first thickness of the walls defining thesecond opening; the plate defining an aperture, sealing a plate to thecase, attaching a terminal to the plate, and sealing the aperture with aplug adapted to conform to the aperture.

This Summary is an overview of some of the teachings of the presentapplication and not intended to be an exclusive or exhaustive treatmentof the present subject matter. Further details about the present subjectmatter are found in the detailed description and appended claims. Otheraspects will be apparent to persons skilled in the art upon reading andunderstanding the following detailed description and viewing thedrawings that form a part thereof, each of which are not to be taken ina limiting sense. The scope of the present invention is defined by theappended claims and their legal equivalents.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a flat capacitor according to one embodiment of the presentsubject matter.

FIG. 2 illustrates a close up view of the plate and plug of FIG. 1.

FIG. 3 illustrates an exploded view of a capacitor, according to oneembodiment of the present subject matter.

FIG. 4A illustrates the front view of a plate, according to oneembodiment of the present subject matter.

FIG. 4B illustrates a cross section taken at line 4B-4B of FIG. 4A.

FIG. 5 shows a side view of conductor attached to a plate with a firstmajor face, according to one embodiment of the present subject matter.

FIG. 6 shows a cross-sectional side view of a feedthrough assembly,according to one embodiment of the present subject matter.

FIG. 7 shows a method for manufacturing an implantable defibrillatoraccording to one embodiment of the present subject matter.

FIG. 8 shows a method for manufacturing an implantable defibrillatoraccording to one embodiment of the present subject matter.

FIG. 9 shows a method for manufacturing an implantable defibrillatoraccording to one embodiment of the present subject matter.

DETAILED DESCRIPTION

The following detailed description of the present invention refers tosubject matter in the accompanying drawings which show, by way ofillustration, specific aspects and embodiments in which the presentsubject matter may be practiced. These embodiments are described insufficient detail to enable those skilled in the art to practice thepresent subject matter. It will be apparent, however, to one skilled inthe art that the various embodiments may be practiced without some ofthese specific details. References to “an”, “one”, or “various”embodiments in this disclosure are not necessarily to the sameembodiment, and such references contemplate more than one embodiment.The following detailed description is, therefore, not to be taken in alimiting sense, and the scope is defined only by the appended claims,along with the full scope of legal equivalents to which such claims areentitled.

FIG. 1 shows a flat capacitor 100, according to one embodiment of thepresent subject matter. The capacitor pictured is useful in a variety ofapplications, including as a power source to provide electricalstimulation in implantable cardioverter defibrillators. In variousembodiments, the capacitor is connected to other components, includingone or more leads which conduct energy from the implantable cardioverterdefibrillator to the patient, a battery to charge the capacitor, andcircuitry used to control the capacitor and to monitor the patient.

Capacitors must include at least one anode element and at least onecathode element, but are not constrained to one shape by design. Variousexamples of capacitors use a set of interconnected anode electrodeelements and a set of interconnected cathode electrode elements. Thepresent subject matter includes, in various embodiments, capacitorswhich are substantially planar, or flat, in shape, comprising anode andcathode elements placed into a stack. One example of a capacitor stackis disclosed in U.S. Pat. No. 6,699,265 to O'Phalen, et al., which isassigned to a common assignee and is incorporated here by reference.Capacitors which are substantially planar, in various embodiments, offera geometry which is beneficial for packaging. Substantially planarcapacitors offer additional benefits as well, such as improvedperformance and manufacturing efficiency. It should be noted, however,that although capacitor 100 is D-shaped and substantially planar, invarying embodiments, the capacitor is shaped differently, includingother symmetrical or asymmetrical shapes.

Capacitor 100 includes a case, which in some embodiments includes atleast two components; a substantially flat surface and connectedsidewalls which form a cup-shaped receptacle, and a substantially flatcover. In various embodiments, the case has one or more openings, andthe cover conforms to one of the openings. In one embodiment, the coveris located approximately parallel to substantially planar surface 102.In one embodiment, the case 114 includes a curvature 116 which allowsthe case to be placed in receptacles which conform to the curvature.Among other benefits, the case is useful to retain electrolyte incapacitors using a fluidic electrolyte. In other words, various examplesof the present subject matter comprise flat capacitors with a number ofelectrodes stacked and placed in a case, with the case filled withelectrolyte.

It should be noted that in various embodiments, the case and coverinclude openings which are formed, in part, by features present in oneor both the cover and the case. For example, in one embodiment, thecup-shaped receptacle includes a semi-circle shaped edge discontinuity,and the cover includes a semi-circle edge discontinuity, and when theyare assembled, they form a circle shaped opening in a case.

In accordance with the design requirement of retaining electrolyte, invarious examples, the case and the cover mate to form a seal. Varyingembodiments use welding to join the case and the cover. For example, inone embodiment, the cover is laser welded to the case 114. In oneembodiment, the weld is performed by an approximately 1064 nm Yag laserhaving an energy range of approximately 2.5 joules to 3.5 joules. Otherembodiments use mechanical locks to join the cover and case, or variousforms of adhesive. Some embodiments use a combination of known joiningmethods, including crimping combined with welding. Preferred designsform a seal between the case and the cover which resists the flow ofelectrolyte.

In various embodiments, the capacitor of the present invention includesan anode conductor 104 and a cathode conductor 106. In variousembodiments, these conductors connect the anode of the capacitor stackand the cathode of the capacitor stack with electronics which arelocated external to the capacitor. In various embodiments, one or bothof these conductors are electrically isolated from the capacitor case.In one example, the case 114 of the capacitor is electrically conductiveand comprises a portion of the cathode. This exemplary variant ismanufactured from aluminum, and is connected to the cathode of thecapacitor stack using a connection means internal to the case 114. Inother embodiments, the case is manufactured using a nonconductivematerial, such as a ceramic or a plastic. It should be noted that thecase can also comprise a portion of the anode.

In embodiments where the capacitor case forms part of a set of capacitorelectrodes, one way to economically connect a conductor to the desiredportions of the capacitor stack is to connect the conductor directly tothe exterior of the case. In various embodiments, attaching an electrodeto the case is facilitated by a plate. One example uses a plate 110which is electrically conductive, and which is laser welded to the case114, placing the plate 110 in electrical communication with the case114. In one embodiment, the weld is performed by an approximately 1064nm Yag laser weld with an energy range of approximately 1.5 joules to2.5 joules. The seal formed by welding a plate to a case, in variousembodiments, is sufficient to restrict the flow of electrolyte. In oneexample, cathode conductor 106 is arc percussion welded to the plate110. In further embodiments, the weld connection is formed usingresistance welding.

In one example, a conductor is held to a plate with a clamping force offrom about 5 to 15 pounds. In the example, the welding process uses acurrent of from about 350 to 500 Amps. The ramp time in the example isfrom about 5 to 15 milliseconds. The time for the weld in the example isfrom about 5 to 15 milliseconds. The gas flow for the example process isfrom about 0 to 8 standard cubic feet per hour. Welding processes,including those taught herein, result in conductor 106 being placed inelectrical communication with a capacitor stack located inside the case.In other words, in one embodiment, the cathode conductor 106 ispercussion welded to the plate 110, which is laser welded to the case114, which is in electrical communication with the cathode of thecapacitor stack placed inside the case 114.

Additionally, in various examples, the plate includes an aperture sealedby a plug. In one example, a plug 108 is laser welded to the plate 110.In one embodiment, the weld is performed by an approximately 1064 nm Yaglaser weld with an energy range of approximately 1.5 joules to 2.5joules. In varying embodiments, the plug and aperture are used to fillthe capacitor case with electrolyte. The seal formed by welding the plugto the plate is, in some examples, sufficient to restrict the flow ofelectrolyte.

Varying embodiments of the present subject matter include a conductorfeedthrough in the case. In various embodiments, a feedthrough enables aconductor to provide a conductive path from the exterior of the case tothe interior of the case, without conducting electricity to the case. Anexemplary embodiment includes a cathodic case 114 and uses a feedthroughto put the anode of the capacitor stack in electrical communication withelectronics external to the case 114, in a manner isolated from thecathodic case. The example uses the anode conductor 104, which passesthrough the feedthrough, to conduct electricity. Because the feedthroughpassageway comprises a hole in the case, in embodiments where thecapacitor is filled with electrolyte, the feedthrough passageway must besealed. To seal the feedthrough passage, various examples include acurable resin disposed between the case and the conductor, the curableresin conforming to the feedthrough passage, and resisting the flow ofelectrolyte. In one example, the curable resin 112 is an epoxyconforming to the feedthrough passageway and bonded to the anodeconductor 104 and the case 114. Varying embodiments form a hermeticseal.

Overall, the present subject matter enables various improvements overthe current art. For example, by eliminating the need to pass one ormore conductors through the case by directly connecting the conductor tothe plate, the cost of capacitor manufacturing can be reduced, andcomplexity affecting reliability and manufacturing can be reduced. Byusing a plate, a capacitor design can include a case of varyingthicknesses. In one embodiment, the thickness of the insert plate is0.030 inches. In varying embodiments, insert plates run fromapproximately 0.020 inches thick to 0.040 inches thick. In varyingembodiments, the insert plate is combined with a case this isapproximately 0.010 inches thick. Additionally, in one embodiments, acase which is from about 0.008 inches thick to about 0.015 inches thick.

For example, in one embodiment, the plate mounts coplanar to theexterior of the case, but extends into the capacitor deeper than doesthe thickness of the case 114. One benefit of this design is that awelding process for connecting a conductor to the case may be used whichrequires material thickness greater than that of the case 114. Forexample, one embodiment uses arc percussion welding with parameterswhich are sufficient to weld a conductor to the plate 110, but whichwould damage the case 114 if the conductor were welded to the case 114.In further embodiments, the weld connection is formed using resistancewelding.

In one example, a conductor is held to a plate with a clamping force offrom about 5 to 15 pounds. In the example, the welding process uses acurrent of from about 350 to 500 Amps. The ramp time in the example isfrom about 5 to 15 milliseconds. The time for the weld in the example isfrom about 5 to 15 milliseconds. The gas flow for the example process isfrom about 0 to 8 standard cubic feet per hour.

As such, the present subject matter allows using a capacitor with a casewhich is too thin for some metal bonding processes, but which isotherwise sufficient to satisfy other requirements of the case, such asretaining electrolyte and a capacitor stack. This design, in variousembodiments, allows for a reduction in case thickness and mass, withoutsacrificing welding options available for connecting the conductor tothe capacitor, ultimately providing for a smaller capacitor, andtherefore, for a smaller implantable device.

FIG. 2 illustrates a close up view 200 of the plate and plug of FIG. 1,according to one embodiment of the present subject matter. In variousembodiments, the capacitor includes case 114. In one embodiment, thecase includes a curvature 116 which is adapted to allow the capacitor tobe placed in a similarly shaped receptacle. The example also includes acathode conductor 106, an anode conductor 104, a curable resin 112, aplate 110, and a plug 108. Additionally, various embodiments include anaperture which extends from the exterior of the case to the interior ofthe case, and which, in some examples, passes through the plate.

In one exemplary embodiment, plate 110 is welded to case 114 forming aseal which restricts the flow of electrolyte. Similarly, the aperture414 is sealed and resists the flow of electrolyte by welding the plug108 to the plate 110, in various embodiments of the present subjectmatter. It should be noted that in other embodiments of the presentsubject matter, the plate is fastened to the case with other fasteningmeans, including a physical lock such as threads. Additionally, the plug108 is fastened to the plate with alternate fastening means, such asthreads. These and other types of fastening designs are within the scopeof the present subject matter, and the list enumerated here is notintended to be limiting.

FIG. 3 illustrates an exploded view of a capacitor 100, according to oneembodiment of the present subject matter. In various embodiments, cupshaped receptacle 314 includes a feedthrough passageway 308 which isformed in a sidewall of the cup shaped receptacle 314. Additionally, acover 204 is adapted for conforming to an opening in the cup shapedreceptacle 314 of the case 114. The feedthrough passageway 308, invarious embodiments, is useful to allow the passage of a conductor whichconnects external circuitry at one end to a capacitor stack at theother. Additionally, in various embodiments, a paper isolating element306 is placed proximal to the feedthrough passageway 308, and internalto the case. For example, in one embodiment, the anode conductor 104passes through the case and connects to the anode of the capacitor stack302. In some embodiments, case 114 includes two or more feedthroughpassageways.

Internal to various embodiments of the assembled capacitor is a terminal304, which is connected to the capacitor stack 302 and to one of thegroup including the cup shaped receptacle 314, the cover 204, or boththe cup shaped receptacle 314 and the cover 204. In various embodiments,a connection between the terminal 304 and the cover 204 is formed bypinching the terminal 304 during assembly of the capacitor stack 302,the cup-shaped receptacle 314, and the cover 204. Various embodimentsconnect terminal 314 to the electrode stack 302 using additional means,such as welding.

In one example, the cathode conductor 106 is connected to the plate 110,which is connected to the cup shaped receptacle, which is connected toterminal 304, which is connected to the cathode of the capacitor stack302. Additionally, a plug 108 is attached to the plate 110.

The capacitor stack 302, in various embodiments, is constructed in ashape which approximates the interior space in the receptacle, in orderto reduce unused space, which can reduce capacitor size, andconcomitantly, device size. One method of reducing device size includeschoosing components in the capacitor stack to adjust the physicaldimensions of the capacitor stack 302. For example, in one embodiment,anode layers are added or subtracted from the stack, resulting in acapacitor stack 302 which matches the interior volume of a particularcase. In this exemplary embodiment, the capacitor stack includes 20cathode layers, and 58 anode layers, but it should be understood thatother embodiments include different numbers of elements.

FIG. 4A illustrates the front view of a plate 110, according to oneembodiment of the present subject matter. In various embodiments, theplate 110 includes an aperture 414. Some embodiments include an aperture414 with a first portion 202, and a second portion 206. Variousembodiments of the first portion 202 and the second portion 206 comprisecoaxial cylindrical shapes with varying diameters. Additionally, variousembodiments of the plate include a first major surface 410.

In various embodiments, the plate 110 is shaped like an irregularpentagon with three rounded adjacent apexes which are approximately 90degrees, and two rounded adjacent apexes which are obtuse angles.However, it should be noted that other plate shapes are within the scopeof the present subject matter.

FIG. 4B illustrates a cross section taken at line 4B-4B of FIG. 4A. Invarious embodiments, the aperture 414 includes a first portion 202.Various examples of the aperture 414 are shaped like a counterbore, withthe first portion 202 comprising a larger diameter, the second portioncomprising a smaller diameter, and the difference between the twodiameters comprising a substantially planar step shape defined by theconcentric circles of the perimeters of the first and second portions.In various embodiments, the first portion 202 opens to the first majorsurface 410. In additional embodiments, the first portion 202 has adepth of t1, and the second portion 206 has a depth which is thedistance of the depth t1 subtracted from the thickness of the plate 110.

In various embodiments, the aperture is adapted to mate with a plug, asis demonstrated by the plate 110 and the plug 108 of the exemplaryillustration of FIG. 2. In various embodiments, the plug 108 roughlymatches the shape defined by the first portion 202 of the aperture 414.In embodiments using the plug to form a seal with the aperture, a plugis selected which includes a thickness which is approximately equal tothe thickness t1. In various embodiments, the surface of the plug isroughly coplanar with the surface of the plate once installed. Variousexamples of the present subject matter affix the plug to the plate 110using welding, an interference fit, adhesive, threads, or variousadditional forms of attachment. On embodiment uses laser welding. In oneembodiment, the weld is performed by an approximately 1064 nm Yag laserweld with an energy range of approximately 1.5 joules to 2.5 joules.

In various embodiments, the plate is adapted to mate with an opening ina case 114, as illustrated in the example of FIG. 1. For instance, inone embodiment, the plate is shaped to restrict its passage through anopening in the case 114. Accordingly, one example of the plate includesa step 402 which divides the plate into a first section with a firstmajor surface 410, and a second section with a second major surface 412.In one embodiment, the first major section 410 is sized for passagethrough an opening in a case 114, and the second major section is sizedso that it cannot pass through the same opening. In one embodiment, theface of the step 402 is positioned proximal to an interior surface ofcase 114, and is further positioned proximal to an opening in the case114.

In various embodiments, the plate includes a thickness t2. In variousembodiments, the thickness t2 is selected to match the thickness of acapacitor case, including the case illustrated in the example of FIG. 1.In examples where t2 matches the thickness of a capacitor case, themajor face 110 is coplanar with the exterior of a capacitor case whenthe plate 110 is attached to the capacitor case.

Generally, the thickness of the plate 110 depends on the type and natureof the contents of the capacitor. In general, a thickness is chosenwhich is compatible with desired manufacturing processes. For example,in embodiments where a conductor is welded to the plate 110, a platethickness is chosen which will result in a final plate shape, afterwelding, which is substantially similar to the shape of the plate priorto the welding process. In other words, in various embodiments, thethickness of the plate is selected to minimize warpage due to thermalstress applied to the plate 110 due to various processes, includingwelding.

In general, the plate can be manufactured by machining, powderedmetallurgy, or by stamping. Additional forming processes are also withinthe scope of the present subject matter. In various embodiments, thetransition between the first portion 202 of the aperture and the secondportion of the aperture 206 is designed with the objective of enablinglaser welding. In some examples, enabling a laser weld requires that thetransition include step shapes which are largely perpendicular. Varyingembodiments of a laser welding process require a step shape to limitlaser energy from extending beyond the welding area. In one embodiment,the weld is performed by an approximately 1064 nm Yag laser weld with anenergy range of approximately 1.5 joules to 2.5 joules.

FIG. 5 shows a side view of conductor 106 attached to a plate 110 with afirst major face 410, according to one embodiment of the present subjectmatter. In various embodiments, the conductor 106 includes a wire 510and a coupling member 512, and one or more arc percussion welding areas,506, 508, 502 and 504. In various embodiments, the wire 510 is attachedto the coupling member 512 using a crimping process, a welding process,or other processes. In one embodiment, the coupling member 512 is arcpercussion welded to the wire at one or more areas. In various examples,areas 506 and 508 are used for applying an arc-percussion weld.Additionally, the coupling member 512 is arc-percussion welded to aplate 110 in various embodiments, and in one embodiment the couplingmember 512 is arc percussion welded at areas 502 and 504. Because of thenature of arc percussion welding, the mating region between the plate110 and the coupling member 512 must be chosen to enable a desired formof weld. In one example, coupling member 512 and plate 110 includesubstantially planar faces which are adapted to mate with each other.

An exemplary arc percussion welding machine is manufactured by MorrowTech Industries of Broomfield, Colo. In this embodiment, the conductor510 and coupling members are not crimped together. However, someembodiments include both welding and crimping.

In further embodiments, the weld connection is formed using resistancewelding. In one example, a conductor is held to a plate with a clampingforce of from about 5 to 15 pounds. In the example, the welding processuses a current of from about 350 to 500 Amps. The ramp time in theexample is from about 5 to 15 milliseconds. The time for the weld in theexample is from about 5 to 15 milliseconds. The gas flow for the exampleprocess is from about 0 to 8 standard cubic feet per hour.

It should be noted that in some embodiments, the wire 510 and thecoupling member are one piece. Additionally, it should be noted thatother forms of conductor 106 which are adapted for percussion welding toa plate 110 are within the scope of the present subject matter.

FIG. 6 shows a cross-sectional side view of details of one embodiment offeedthrough assembly 620. In some examples, a means is available forconnecting the capacitor stack contained in the case to electronicswhich are located outside of the case. In some of these embodiments, theconnecting means is of one polarity, and the capacitor case is ofanother polarity. In these embodiments, it is necessary to provide astructure for allowing electricity to pass through the case wall withoutcontacting the case wall. In various embodiments, the feedthroughassembly 620 demonstrates one embodiment adapted for providing this. Invarying examples, the feedthrough assembly 620 includes a feedthroughpassageway 308 which is drilled, molded, punched, or otherwise formed ina portion of a sidewall of the case 114. Additionally, in someembodiments, the feedthrough passageway is located in a plate, or islocated partially in a case and partially in a plate. For example, inone embodiment, one half of a feedthrough passageway is located in aplate or cover and one half of a feedthrough passageway is located in acase.

In some embodiments, the feedthrough assembly 620 includes an anodeconductor 104 which is attached to the anode of the capacitor. Varyingembodiments of the capacitor anode include one or more anode members 608which are coupled to anode conductor 104 for electrically connecting theanode to circuitry outside the case 114. In one embodiment, anodemembers 608 are edge-welded to each other. Edge-welding the anodemembers 608, in various embodiments, provides a flat connection surface410. In some embodiments, anode members 608 are crimped or soldered, andin further embodiments, the anode members 608 are connected by anelectrically conductive adhesive or by other means.

In some embodiments, a wire 604 is coupled to a coupling member 606,forming, in part, an anode conductor 104. Various embodiments of thepresent subject matter include attaching the wire 604 to the couplingmember 606 using soldering, welding, crimping, and other methodssufficient to connect the wire 604 to the coupling member 606, invarying embodiments. In one embodiment, anode conductor 104 is a single,substantially unified metallic crystalline member.

In one embodiment, coupling member 606 is a high-purity aluminum memberwhich is able to withstand the high voltages generated within thecapacitor case. In other embodiments it is made from another conductivematerial compatible with the capacitor stack 302. In variousembodiments, one side of the coupling member 606 includes a planarsurface for attaching to the planar surface 610 presented by edge-weldedcapacitor stack 608.

In one embodiment, coupling member 606 is laser welded to surface 610 ofcapacitor stack 302 using a butt-weld. Alternatively, coupling member606 is attached using other means. Butt-welding coupling member 606directly to capacitor stack 302 provides an electrical connectionbetween capacitor stack 302 and the conductor. Also, since couplingmember 606 is directly attached to capacitor stack 302, it supports theconductor while a curable resin 112, such as an epoxy, is applied to thefeedthrough passageway area.

In one embodiment, feedthrough passageway 308 is in part defined by anedge which is tapered to improve the surface area available to a bondingagent. Curable resins bond to surfaces, and as such, can create a largerbonding areas when applied to a larger surface area. A larger bond, invarious embodiments, is more robust, reliable, and is less likely topermit leaks. Additionally, in one embodiment, a larger bonding area canincrease the distance between the coupling member and the case byincluding a larger feedthrough passage. Accordingly, increased area canreduce instances of unwanted arcing. A tapered edge, in variousembodiments, includes these benefits. For example, in one embodiment, afeedthrough passageway includes an inbound narrowing sidewall 624extending to a lip 622. In various embodiments, a cavity is defined bythe sidewall 624, the coupling member 606, and an isolating element 306.A curable resin 112, in various embodiments, is disposed in the cavityand hardened, and serves to insulate the case 114 from the anodeconductor 104, and further serves as a seal to resist the flow ofelectrolyte 602. For example, in one embodiment, the conductor is anuninsulated anode conductor 104 connected to the anode of the capacitorstack, the anode conductor 104 passing through a feedthrough passageway308 in a cathodic case 114. In this exemplary embodiment, a curableresin 112 is used to seal electrolyte 602 into the capacitor, and isfurther used to insulate the anodic elements, such as the coupling 606,from the cathodic elements, such as the case 114. In one example, thecurable resin 112 is a hardened two-part quick-setting thermal-setepoxy.

In one embodiment, an isolating element 306 is combined with theconductor 104, the feedthrough passageway 308, and the curable resin112. This combination, in various embodiments, in useful for restrictingthe flow of electrolyte 602, curable resin 112, or both. In variousembodiments, the isolating element 306 is a paper washer which assistsin limiting the flow of curable resin 112 to a desired area. One benefitof using an isolating element 306 to restrict the flow of a curableresin, such as epoxy, is that the epoxy is less likely to flow intoother locations within the capacitor, which can adversely affectcapacitor performance.

In varying embodiments, the feedthrough passageway 308 is assembled tothe capacitor stack and seals to the capacitor stack surface 610, and inadditional embodiments, the feedthrough passageway 308 seals to thecoupling member 606. In one embodiment, the feedthrough passageway 308includes a lip 622 adapted for forming a circular seal with the couplingmember 606. In various embodiments, because of the nature of assembly,including imperfect manufacturing tolerances and imperfect surfacefinishes, the effectiveness of the seal formed between the feedthroughpassageway 308 and the coupling member 606 is limited. To increase theeffectiveness of the seal, in various embodiments, an isolating element306 is located between the feedthrough passageway 308 and the couplingmember 606 which is compressible, and which resists the flow ofelectrolyte and resists the flow of epoxy. In one embodiment, theisolating element 306 is constructed from paper which is of a thicknesswhich can absorb manufacturing irregularities, such as surface finishirregularities and manufacturing tolerance irregularities, whileproviding a seal.

In additional embodiments, the isolating element 306 is useful forproviding electrical insulation between the case 114 and the anodeconductor 104. In varying embodiments, the element is made out ofseparator paper, and in one example, it is made out of Kraft paper. Forexample, in various embodiments, the case is cathodic, and an anodiccoupling 606 must be electrically isolated from the case 114 for thecapacitor to function. Additionally, in various embodiments, to reducethe size of the capacitor, the anode conductor 104 and the case 114 areplaced near one another. Therefore, in various embodiments, to reduceinstances of arc between the case and the anodic conductor 104, aninsulative element 306 is disposed between the case 114 and the anodeconductor 104.

In various embodiments, a curable resin 112 is any of numerous clear totranslucent yellow or brown, solid or semisolid, viscous substances ofplant origin, such as copal, rosin, and amber, used principally inlacquers, varnishes, inks, adhesives, synthetic plastics, andpharmaceuticals. Additionally, curable resin 112 includes any ofnumerous physically similar polymerized synthetics or chemicallymodified natural resins including thermoplastic materials such aspolyvinyl, polystyrene, and polyethylene and thermosetting materialssuch as polyesters, epoxies, and silicones that are used with fillers,stabilizers, pigments, and other components to form plastics. It shouldbe noted that the sealing members listed here are not a complete list ofthe sealing members within the scope of the present subject matter. Forexample, various examples include sealing members which provide anon-hermetic seal, and one embodiment includes a substantially elasticplug.

An exemplary curable resin 112 is an epoxy which is a two-part epoxymanufactured by Dexter Hysol. This includes a casting resin compound(manufacturer No. EE 4183), a casting compound (manufacturer No. EE),and a hardener (manufacturer No. HD 3404). The exemplary two-part epoxyis mixed in a ratio of hardener=0.055*casting resin. The mixture iscured at 0.5 hours at 60 degrees Celsius or 1.5 hours at roomtemperature. Another epoxy is a UV cure epoxy such as manufactured byDymax, Inc., which can be cured using an Acticure (manufactured byGenTec) ultraviolet curing system at 7 W/cm² at a distance of 0.25inches for approximately 10 seconds.

It should be noted that the embodiments enumerated here, in which ananode conductor passes through a feedthrough assembly, are only examplesof the present subject matter. Additional embodiments include a cathodeconductor passing through a passageway in an anodic capacitor case.Further, additional embodiments include multiple feedthrough passages,and some include a case which is neither anodic nor cathodic.

FIG. 7 shows a method 700 for manufacturing an implantable cardioverterdefibrillator according to one embodiment of the present subject matter.In various embodiments, the method includes providing a capacitorreceptacle with at least two openings 702. For example, variousembodiments include a cup-shaped receptacle, with a major surface andside-walls extending from the surface and forming a dish-shaped volume.In one embodiment, the receptacle side-walls include two openings: afirst opening which is adapted for mating with a plate, and a secondopening which is adapted for mating with a cover. In variousembodiments, the receptacle is a conductive metal, and in oneembodiment, the receptacle is aluminum.

In various embodiments, the method includes attaching a plate to one ofthe openings in the receptacle 704. In various examples, the plate issized for mating with the first opening. In some examples, the plate issubstantially planar, and cannot pass through the first opening whenpositioned approximately parallel to the sidewall which includes theopening. Additionally, in various embodiments, the plate is sizedthicker than the sidewall of the receptacle. In embodiments where thesidewall is not of a uniform thickness, the plate is thicker than atleast part of the sidewall proximal to the opening to which the plate isattached.

Varying embodiments attach the plate using a welding process. In oneembodiment, the plate is attached using a laser welding process. In oneembodiment, the weld is performed by an approximately 1064 nm Yag laserweld with an energy range of approximately 1.5 joules to 2.5 joules. Inother embodiments, the plate is attached to the receptacle using othermeans, such as threads or a mechanical lock. In various forms, attachingthe plate to the receptacle forms a seal, and in some embodiments theseal resists the flow of electrolyte.

Various embodiments of the present subject matter include a plateadapted for attachment of a terminal. Various embodiments includeattaching a terminal to the plate 706. For example, in variousembodiments, a terminal is welded to the plate. In one embodiment, aterminal is percussion welded to the plate. In various embodiments, theparameters of the percussion weld require a plate of a minimumthickness, and the plate is sized to approximate that thickness. Bysizing the plate to approximately match the required parameters of thewelding process, only a portion of the capacitor case is produced atthat thickness, allowing the remaining portions, which are not welded,to be thicker or thinner. In one embodiment, a thinner receptacle isused, which results, in various embodiments, in a capacitor which issmaller and lighter.

In various examples, a capacitor stack is placed in the capacitorreceptacle through the second opening 708. Additionally, variousembodiments include attaching a cover to the second opening 710.Attaching the cover includes, in various embodiments, welding the coverto the receptacle. In one embodiment, a seal is created using a laserwelding process which resists the flow of electrolyte.

Various embodiments also include filling the receptacle with electrolyte712, and sealing the receptacle to resist the flow of electrolyte 714.For example, in one embodiment, an aperture provides access to theinterior volume formed by attaching the plate and the cover to thereceptacle. In various embodiments, the aperture is the only access tothe interior of the capacitor case which does not resist the flow ofelectrolyte. In various embodiments, the method of the present subjectmatter includes filling the volume with electrolyte. For example, invarious embodiments, the volume is filled, and later pressurized toencourage the escape of gasses from the interior volume of thecapacitor. In one embodiment, the gases escape through the aperture.Various embodiments include sealing the aperture after the capacitor hasbeen filled with electrolyte to resist the flow of electrolyte.

FIG. 8 shows a method 800 for manufacturing an implantable cardioverterdefibrillator, according to one embodiment of the present subjectmatter. For example, in various embodiments, a receptacle is providedwith a first opening and a second opening 802. In some embodiments, aplate is inserted 804 into the receptacle and attached 806 to the firstopening. In one embodiment, the plate is substantially planar and issized so that it cannot pass through the first opening when positionedapproximately parallel to the plate formed by the perimeter of theopening.

In various embodiments, the plate includes an aperture. In oneembodiment, the plate is inserted and attached to the receptacle, acapacitor stack is installed in the receptacle 808, and a cover isattached to the receptacle 810. The exemplary embodiment is assembledforming a seal which resists the flow of electrolyte, excluding theaperture. Various examples which are sealed to resist the flow ofelectrolyte are filled with electrolyte 812, which substantiallyimpregnates the interior volume of the capacitor case. Various examplesuse a pressure differential to encourage the impregnation of theinterior volume of the capacitor with electrolyte.

Various examples plug the aperture with a member 814, which can beattached in a number of ways, including welding, interference fit,threading, and other means suitable for forming a sealed attachment. Inone embodiment, the aperture is sealed by laser welding a disc shapedplug into a similarly shaped counterbore in the aperture.

FIG. 9 shows a method 900 for manufacturing an implantable cardioverterdefibrillator according to one embodiment of the present subject matter.In various embodiments, the method of the present subject matterincludes assembling a stack with at least one terminal 902. In variousembodiments, a paper isolating element 306 is assembled to the terminal904. In one exemplary embodiment of the present subject matter a paperwasher is inserted onto a terminal which is shaped like a boss.

In various embodiments, the assembled capacitor stack is placed into areceptacle with a first opening and a second opening 906. Variousexamples of the method of the present subject matter include aligningthe terminal with the first receptacle opening. One example includesaligning the terminal with the first receptacle opening so that theterminal passes at least part of the way through the receptacle opening.

Various embodiments attach a cover to the second receptacle opening 909.Various embodiments include attaching the cover using a welding process,including laser welding. Additional embodiments include attaching thecover with various additional methods, including using mechanical locks,rivets, fasteners, or other forms of fastening methods. In variousembodiments, attaching the cover to the second receptacle openingincludes forming a seal between the cover and the receptacle. In oneexample, the seal is adapted for resisting the flow of electrolyte.

In various embodiments, a sealing member is used to seal the terminal tothe first opening 910. For example, in various embodiments, an epoxy isused to seal the space between the terminal and the first opening. Inone exemplary embodiment of the present subject matter the paperisolating element 306 is adapted to interface with the first opening andthe terminal to form a seal which is adapted to localize the epoxyproximal to the interface between the paper insert, the terminal, andthe second opening. In other words, the paper isolating element 306 isadapted to limit the epoxy to wetting proximal to the terminal, thefirst opening, and the paper insert.

It should be noted that the methods of the present subject matter, invarious embodiments, include inserting the assembled capacitor into animplantable medical device suited for delivering electrical stimulationto a patient. In one embodiment, the method of the present subjectmatter includes installing a capacitor in a implantable cardioverterdefibrillator which is adapted for implant in a patient, and which isalso adapted to deliver high voltage pulses to a patient in order topromote cardiac wellness. For example, in various embodiments, onemethod of the present invention includes providing a defibrillator casehaving circuitry disposed in the case. Additionally, various embodimentsinclude implanting an implantable cardioverter defibrillator in apatient. Also, some examples include connecting the cardiac system of apatient to the implantable cardioverter defibrillator. In one example,circuitry in the capacitor controls the discharge of electrical energyfrom the capacitor to the patient. Overall, in various embodiments, themethod of the present invention enables improved delivery of electricalstimulation to a patient using an implantable cardioverterdefibrillator.

Although specific embodiments have been illustrated and describedherein, it will be appreciated by those of ordinary skill in the artthat any arrangement which is calculated to achieve the same purpose maybe substituted for the specific embodiment shown. This application isintended to cover adaptations or variations of the present subjectmatter. It is to be understood that the above description is intended tobe illustrative, and not restrictive. Combinations of the aboveembodiments, and other embodiments will be apparent to those of skill inthe art upon reviewing the above description. The scope of the presentsubject matter should be determined with reference to the appendedclaims, along with the full scope of equivalents to which such claimsare entitled.

1. A method, comprising: assembling a capacitor stack out of electrode layers; placing the capacitor stack in a case that defines a first opening and a second opening, the first opening sized for the passage of the capacitor stack, the second opening defined by walls having a first thickness; inserting a plate into the second opening from the inside of the case, the plate adapted to mate to the second opening, and having a thickness which is approximately greater than the first thickness of the walls defining the second opening, the plate defining an aperture; sealing the plate to the case; attaching a terminal to the plate, and sealing the aperture with a plug adapted to conform to the aperture.
 2. The method of claim 1, including measuring the thickness of the case, and selecting a plate sized to be coplanar with the exterior of the case after insertion.
 3. The method of claim 1, including using a laser to create the seal between the plate and the case.
 4. The method of claim 1, further comprising injecting a fluidic electrolyte into the case through the aperture.
 5. The method of claim 1, wherein the plate includes an aperture with a counterbore.
 6. The method of claim 5, wherein the plug is plate-like and has a perimeter which is larger than the boundary of the aperture and wherein sealing the aperture includes inserting the plug into the counterbore and bonding the plug to the plate.
 7. The method of claim 6, wherein the bond is created using a laser.
 8. The method of claim 1, wherein the terminal is bonded to the plate.
 9. The method of claim 8, wherein the terminal is arc percussion welded to the plate.
 10. A method, comprising: assembling an aluminum electrolytic capacitor stack comprising electrode layers by stacking at least one separator layer onto at least one anode layer, and by stacking at least one cathode layer onto the at least one separator layer; placing the capacitor stack in a case that defines a first opening and a second opening, the first opening sized for the passage of the capacitor stack, the second opening defined by walls having a first thickness; inserting a plate into the second opening from the inside of the case, the plate adapted to mate to the second opening, and having a thickness which is greater than the first thickness of the walls defining the second opening, the plate defining an aperture; sealing the plate to the case; attaching a terminal to the plate, and sealing the aperture with a plug sized to conform to the aperture.
 11. The method of claim 10, including laser welding the plate to the case.
 12. The method of claim 11, wherein sealing the aperture includes welding the plug to the plate.
 13. The method of claim 11, further comprising bonding the terminal to the plate.
 14. The method of claim 13, wherein bonding the terminal includes arc percussion welding the terminal to the plate.
 15. The method of claim 10, further comprising counterboring the plate, and wherein the plug is plate shaped and has a perimeter that is larger than the boundary of the aperture.
 16. A method, comprising: assembling a capacitor stack out of electrode layers by stacking a plurality of substantially planar anode layers into an anode element, and stacking the anode element with a substantially planar cathode, with at least one separator layer disposed between the anode element and the cathode; placing the capacitor stack in a case that defines a first opening and a second opening, the first opening sized for the passage of the capacitor stack, the second opening defined by walls having a first thickness; inserting a plate in the second opening from the inside of the case, the plate adapted to mate to the second opening, and having a thickness which is approximately greater than the first thickness of the walls defining the second opening, the plate defining an aperture; sealing the plate to the case; attaching a terminal to the plate, and sealing the aperture with a plug sized to conform to the aperture.
 17. The method of claim 16, wherein inserting the plate includes inserting it so that the plate is substantially coplanar with the exterior of the case after insertion.
 18. The method of claim 16, further comprising injecting electrolyte into the case through the aperture before sealing the aperture with the plug.
 19. The method of claim 16, wherein sealing the aperture includes welding the plug to the plate.
 20. The method of claim 16, wherein bonding the terminal includes arc percussion welding the terminal to the plate. 